Recycling method, and image forming apparatus manufactured using recycling method

ABSTRACT

A recycling method in an apparatus having a part includes a part removal step of removing a part from the apparatus, and a mounting step of mounting to the apparatus a part having a specification different from that of the removed part.

FIELD OF THE INVENTION AND RELATED ART

The present invention relates to a recycling method (remanufacturingmethod: REM or RMF), in which products used in the market place arerecovered, disassembled, sorted, and reassembled to manufacture productsvirtually identical to the original, or products different from theoriginal. In particular, it relates to an image forming apparatusrecycling method.

It has been a common practice for manufacturers to recover their usedproducts from the market place, due to environmental concerns. Therecovered used products were disassembled, and sorted. The componentswhich could be reused as they were, were reused. Some of those whichcould not be reused as they were, were used as the material for newproducts, or used as fuel, and the others were dumped after beingreduced in volume by pulverization, burning, or the like.

In the past, however, the usage of the recycled products has beenlimited to the remanufacture of the products identical to the recoveredproducts, or the products which are common in some components with therecovered products. In other words, the number of the recyclableproducts has been limited.

Further, recycling incurs the expense for recovery and disassembly, aswell as the expense for determining whether or not the recovered usedproducts are reusable. Thus, not all products have been recycled; someof them have been discarded.

Further, the amount of recyclable products has been limited. Therefore,the amount of recyclable products necessary to be recovered forrecycling has fluctuated. In other words, as the amount of a shipmentdecreased, there was an excessive amount of the recovered recyclableproducts, whereas as the amount of a shipment increased, there was ashortage of the recovered recyclable products (in other words, shortageof recovered reusable components), forcing the manufacturers to usebrand-new components for the remanufacture of the recyclable products.In other words, a fresh supply of recyclable components have beenmanufactured for the purpose of remanufacture. Further, as the productsof the next generation come onto the market after the ending of themanufacture of the preceding generation resulting from the drop in theprices of the products of the preceding generation, the recoveredrecyclable products of the preceding generation and/or the componentstherefrom could not be used, ending up in the dump. In addition, theprocesses used for recycling the recyclable products of the precedinggeneration had to be modified for the recyclable products of the newgeneration. This generational switch resulted in additional wasteproducts.

Some image forming apparatuses are made up of a plurality of functionalunits necessary for image formation, and a frame to which the pluralityof functional units are attached. Therefore, as long as the units and/orcomponents therefrom are reused for manufacturing such image formingapparatuses that are identical to the image forming apparatuses fromwhich they were extracted, they were easy to recycle. However, the unitsand/or components therefrom were not easy to recycle when it came to thematter of reusing them to manufacture image forming apparatusesdifferent in specification from the image forming apparatuses from whichthey were extracted, that is, image forming apparatuses different intheir external shape, portions of the frame to which they are attached,combination in which they are assembled, and the like matters. Thus, inthe latter case, the units and/or components which could not be reusedhad be discarded, reducing the ratio at which the units and/orcomponents from the recovered used image forming apparatuses wererecycled.

SUMMARY OF THE INVENTION

The primary object of the present invention is to provide a recyclingmethod which makes it possible for a recovered component to be reusednot only for the remanufacture of an apparatus identical inspecification to the product from which the component was extracted, butalso for the manufacture of products different in specification from theproduct from which the component was extracted, and also, to provide animage forming apparatus which can be remanufactured or manufacturedusing such a recycling method.

According to one of the preferable embodiments of the present inventionfor accomplishing the above described object, a method for recycling anapparatus comprising a plurality of components comprises: a componentremoving process for removing certain components from a recoveredapparatus; and a component attaching process for attaching componentsdifferent in specification from those certain components removed fromthe recovered apparatus, to the recovered apparatuses from which thecertain components were removed.

According to another preferable embodiment of the present invention, animage forming apparatus comprising a plurality of components isrecyclable through the following processes: a component removing processfor removing certain components from a recovered apparatus; and acomponent attaching process for attaching components different inspecification from those certain components removed from the recoveredapparatus, to the recovered apparatus from which those certaincomponents were removed.

These and other objects, features, and advantages of the presentinvention will become more apparent upon consideration of the followingdescription of the preferred embodiments of the present invention, takenin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a chart for showing an image forming apparatus recyclingprocess.

FIG. 2 is a drawing for showing Example 1 of a specificationmodifying/manufacturing process.

FIG. 3 is a drawing for showing Example 2 of a specificationmodifying/manufacturing process.

FIG. 4 is a drawing for showing Example 3 of a specificationmodifying/manufacturing process.

FIG. 5 is a drawing for showing the first embodiment of the presentinvention.

FIG. 6 is a drawing for showing the second embodiment of the presentinvention.

FIG. 7 is a drawing for showing the third embodiment of the presentinvention.

FIG. 8 is a drawing for showing the fourth embodiment of the presentinvention.

FIG. 9 is a drawing for showing the fifth embodiment of the presentinvention.

FIG. 10 is a drawing for showing the sixth embodiment of the presentinvention.

FIG. 11 is a drawing for showing the seventh embodiment of the presentinvention.

FIG. 12 is a drawing for showing the eighth embodiment of the presentinvention.

FIG. 13 is a drawing for showing the ninth embodiment of the presentinvention.

FIG. 14 is a drawing for showing the configuration of the supportingmember.

FIG. 15 is a sectional view of the image forming apparatus in the tenthembodiment of the present invention.

FIG. 16 is a perspective view of the image forming apparatus in FIG. 15,from which the exterior panels were removed.

FIG. 17 is a perspective view of the image forming apparatus, from whichthe exterior panels were removed, and the front panel of the main frameof which is outlined by double-dot chain lines in order to give theimpression that the front plate is transparent.

FIG. 18 is a perspective view of only the main frame of the imageforming apparatus in FIG. 15.

FIG. 19 is a perspective view of the main frame recycled from the imageforming apparatus in FIG. 15, and the functional units which aredifferent in configuration and/or positioning from those in the imageforming apparatus in FIG. 15.

FIG. 20 is a perspective view of the main frame recycled from the imageforming apparatus in FIG. 15, and the functional units different inconfiguration and/or positioning from those in FIGS. 15 and 19.

FIG. 21 is a sectional view of an image forming apparatus comprising themain frame recycled from the image forming apparatus in FIG. 15, and thefunctional units different in configuration and/or positioning.

FIG. 22 is a sectional view of another example of an image formingapparatus.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a chart for an image forming apparatus recycling method inaccordance with the present invention. Designated by referential codes1, 2, 3, 4, 5, and 6 are: a recovering process; a receiving process; adisassembling/cleansing process; a sorting/examining process; aspecification modifying/manufacturing process; and a selling process,respectively.

The products recovered from users are processed in the receiving process2; they are subjected to a simple examination to determine theirspecifications. For example, some of them are classified as an M type:black-and-white analog copying machine.

After being classified as the M type, they are transferred to thedisassembling/cleansing process 3, in which they are disassembled intoframes, units, components, and the like, and are cleansed.

In the sorting/examining process 4, the frames, units, components, andthe like, disassembled from the recovered apparatuses are checked fordefects, and then, are sorted. Those with problems are repaired forreuse.

Then, those restored to the state in which they can be reused, are sentto the specification modifying/manufacturing process 5.

In the specification modifying/manufacturing process 5, theirspecifications are modified to specifications different from thespecifications which belonged to them when they were attached to theoriginal apparatuses. For example, the new specifications are:specification A: high speed digital color copying machine; specificationB: medium speed digital color copying machine; specification C: lowspeed digital color copying machine; specification D: high speed digitalblack-and-white copying machine; specification E: medium speed digitalblack-and-white copying machine; specification F: low speed digitalblack-and-white copying machine; and the like.

Incidentally, specification modification adds to the cost of some of theaforementioned processes. Thus, the specifications may be modified toincrease the values of the apparatuses of the next generation, so thatthe profitability can be secured by the value added by the specificationmodification made in these processes, in spite of the cost increasesincurred by the specification modification.

The modifying/manufacturing process 5 prevents the usage of therecovered components from being limited to the remanufacturing ofproducts identical to the products from which the components wererecovered. In other words, the modifying/manufacturing process 5 makesit possible for the recovered components to be used for apparatusesother than the apparatuses from which they were extracted. Thus, even ifthe amount by which one of the various models of apparatuses ismanufactured fluctuates, the frames, units, components, and the likefrom the recycled apparatuses of this model can be used for themanufacturing of the other models, stabilizing the recycling operation.

Also, with the provision of the modifying/manufacturing process 5, evenafter the apparatuses of the new generation take over the markets towardthe end of the life cycle of the apparatuses of the precedinggeneration, those recovered from the apparatuses of the precedinggeneration can be used for the manufacturing of the new generation,extending the service lives of the components from recyclableapparatuses.

Further, the provision of the process 5 makes it unnecessary for theother processes in the recycling method to be modified, eliminating thewaste traceable to product cycle.

The products manufactured through the specificationmodifying/manufacturing process are sold to users (selling process 6).

FIGS. 2-4 show examples of the specification modifying/manufacturingprocess.

[Example 1 of Specification Modifying/Manufacturing Process] (FIG. 2)

In this example, a recovered image forming apparatus is disassembled,and the components therefrom are sorted. Then, the original front, back,and side plates are removed from the frame 1, and front, back, and sideplates 11, 12, and 13 different in specification from the originalplates removed from the frame 1 are attached to the frame 1 to make theframe 1 reusable.

Referring to FIG. 2, designated by referential codes a, b, and c are:bottom plate, front plate, and back plate, of the frame 1. Designated byreferential codes d and e are top right stay and bottom right stay, towhich the front and rear plates b and c are solidly fixed, whereasdesignated by referential codes f and g are top left stay and bottomleft stay, to which the front and back plates b and c are solidly fixed.Designated by a referential code h is a caster attached to the bottomplate a of the frame 1.

The recovered frame is modified in specification so that after themodification, the recovered frame matches the specification of an imageforming apparatus of the next generation, that is, the generation afterthe generation to which the image forming apparatus from which the framewas removed belongs. After the modification, the recovered frame isreused for manufacture of an image forming apparatus of the nextgeneration. Sometimes, the recovered frame is modified in specificationso that after the modification, the recovered frame matches thespecification of a modified version of an image forming apparatus of thesame generation. After the modification, the recovered frame is reusedfor the manufacture of a modified version of an image forming apparatusof the same generation.

The component anchoring portion of the recovered frame 1, to which arecovered and modified component, or a brand-new component, is attached,may be the same as the component anchoring portion of the recoveredframe 1, from which the original component was removed, or the frame 1may be provided in advance with a plurality of component anchoringportions, to which a component, which is the same in function but isdifferent in specification, can be attached, so that the recovered andmodified component, or a brand-new component, which is substantially thesame in function as the original component but is different inspecification, can be readily attached to the recovered frame tomanufacture a product different in specification from the product fromwhich the frame 1 was extracted. Further, a product may be designed sothat the modified version of a given original component of the product,or a brand new component which replaces the given original component,can be readily attached to the component anchoring portion of the frame,from which the original component was removed, and that the componentanchoring portion of the frame to which the given original component isattached is made different from the component anchoring portions towhich the components other than the given component are attached.

[Example 2 of Specification Modifying/Manufacturing Process] (FIG. 3)

In this example, a recovered image forming apparatus is disassembled,and the components therefrom are sorted. Then, a portion 14 of the frame1 is processed by a laser to make the frame 1 reusable. In other words,the recovered frame 1 is modified in specification by a laser in orderto make the frame 1 reusable for the manufacture of a product differentin specification from the product from which the frame 1 was removed.

That is, in order to make the frame 1 from a recovered image formingapparatus of the preceding generation meet the specification of an imageforming apparatus of the next generation, the portion 14 of the frame 1of the recovered image forming apparatus is processed so that the frame1 from the recovered image forming apparatus of the preceding generationcan be used for the manufacture of an image forming apparatus of thenext generation, or in order to make the frame 1 of the recovered imageforming apparatus of the current generation meet the specification of amodified version of an image forming apparatus of the currentgeneration, the portion 14 of the frame is processed so that the frame 1from the recovered image forming apparatus can be used for themanufacture of a modified version of an image forming apparatus of thecurrent generation.

[Example 3 of Specification Modifying/Manufacturing Process] (FIG. 4)

In this example, in order to use a plurality of recovered components toproduce a component different in specification from the plurality ofcomponents, the plurality of recovered components are combined in amanner different from the manner in which they were originally combined.

Referring to FIG. 4(a), the recovered waste toner container 2 can be cutinto three pieces: main section 2 a, left plate 2 b, and right plate 2b. Next, referring to FIG. 4(b), a main section 2 a, the right plate ofwhich has been removed, and a main section 2 a, the left plate of whichhas been removed, are connected (gluing or welding) by the edges oftheir openings created by the removal of their side plates, to produce awaste toner container 2A different in specification from an originalwaste toner container, that is, a waste toner container larger incapacity.

As described above, this example is a method for using a plurality ofrecovered components to produce a new component (2A) different inspecification from any of the recovered components.

Embodiment 1

FIG. 5 is a drawing which best shows the characteristics of thisembodiment. In the drawing, referential codes 1, 2, and 3 stand for thebottom, front, and rear plates of the main frame of an image formingapparatus or the like. Designated by referential codes 4 and 5 are thetop right stay of the main frame, to which the front and rear plates 2and 3 of the main frame are solidly attached, and the bottom right stayof the main frame, to which the front and rear plates of the main frameare solidly attached, respectively. Designated by referential codes 6and 7 are the top left stay of the main frame, to which the front andrear plates 2 and 3 of the main frame are solidly attached, and thebottom left stay of the main frame, to which the front and rear plate 2and 3 of the main frame are solidly attached, respectively. Designatedby a referential code 8 is a caster attached to the bottom plate 1 ofthe main frame.

This embodiment is an example of a recycling method characterized inthat in order to recycle the main frame of the recovered image formingapparatus, the original front plate 2 of the main frame is replaced witha front plate 9, which is partially different from the original frontplate 2; the portion 9 a of the replacement front plate 9 is differentin configuration from the portion 2 a of the original front plate 2.

In this embodiment, the present invention was described with referenceto only the front plate 2 (9) of the main frame of an image formingapparatus. However, replacement does not need to be limited to the frontplate 2 of the main frame. In other words, replacing a single orplurality of the structural components of the main frame other than thefront plate 2, instead of, or as well as, the front plate 2, is notdiscordant with the gist of the present invention.

Embodiment 2

FIG. 6 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 5 are given the same referential codes as thosegiven in FIG. 5 to avoid the repetition of the same descriptions.

This embodiment is an example of a recycling method characterized inthat the front plate 2 of the main frame is partially modified. Morespecifically, for the purpose of recycling the main frame of the imageforming apparatus, the front plate 2 of the main frame is processed toprovide the portion 2 a of the front plate 2 with a rectangular holeidentical to the rectangular hole 9 a of the front plate 9 shown in FIG.6.

A referential code 2 a stands for the portion of the front plate 2before the front plate 2 is process for recycling, and the referentialcode 9 a stands for the rectangular hole identical to the rectangularhole which will be cut through the portion 2 a of the front plate 2.Although in this embodiment, only a single rectangular hole is cutthrough the portion 2 a of the front plate 2, the number of the holesmay be two or more, and the shape of the hole may be different from thatof the shape of the hole cut in this embodiment. Further, the portion orportions of the main frame which are modified for recycling may be thoseother than the front plate 2. In other words, modifying a single orplurality of the portions of the main frame other than the portion 2 aof the front plate 2 in this embodiment, instead of, or as well as, theportion 2 a, is not discordant with the gist of the present invention.

Embodiment 2

FIG. 7 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 5 are given the same referential codes as thosegiven in FIG. 5 to avoid the repetition of the same descriptions.

A referential code 10 stands for a flat plate which constitutes a partof the front member 2 of the main frame. Referential codes 12 and 13stand for a couple of flat plates which constitute the parts, one forone, of the rear member 13 of the main frame.

This embodiment is an example of a recycling method characterized inthat in order to make the front plate 2 of the recovered main framerecyclable, the flat member 10, which constitutes a part of the frontmember 2 of the recovered main frame, is replaced with a flat plate 11which is partly different in configuration from the flat member 10.

The portion 11 a of the flat plate 11 which replaces the flat plate 10constituting a part of the front member 2 is different in configurationfrom the portion 10 a of the flat plate 10.

Although this embodiment of the present invention was described withreference to the front member 2 of the main frame, this embodiment isnot intended to limit the application of the present invention to thefront member 2 of the main frame. In other words, replacing a single, orplurality, of the members of the main frame other than the front member2, instead of, or as well as, the front member 2, is not discordant withthe gist of the present invention.

Embodiment 4

FIG. 8 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 7 are given the same referential codes as thosegiven in FIG. 7 to avoid the repetition of the same descriptions.

This embodiment is an example of a recycling method characterized inthat in order to recycle the front member 2 of the recycled main frame,the flat plate 10 constituting a part of the front member 2 is processedto provide it with a rectangular hole identical to the rectangular hole11 a of the flat member 11 shown in FIG. 8, partly modifying inconfiguration the flat plate 10 of the front member 2 of the main frameprior to recycling.

Designated by a referential code 10 a is a portion of the flat plate 10before it is processed, whereas designated by a referential code 11 a isthe hole similar to the hole given to the portion 10 a of the flat plate10 by the processing.

Although this embodiment was described with reference to the addition ofthe rectangular hole 10 a, it was not intended to limit the scope of thepresent invention. In other words, the shape of the hole may bedifferent from the shape given in this embodiment, and the number of theholes may be two or more. Further, the modification does not need to belimited to the front member 2. In other words, modifying the structuralmembers of the main frame other than the front member 2, instead of, oras well as, the front member 2, is not discordant with the gist of thepresent invention.

Embodiment 5

FIG. 9 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 7 are given the same referential codes as thosegiven in FIG. 7 to avoid the repetition of the same descriptions.

Designated by referential codes 14 and 15 are positioning pins forpositioning a flat plate 12, which constitutes the rear plate of themain frame, relative to the rear member 3 of the main frame, whereasdesignated by referential codes 16 and 17 are holes of the rear member 3of the main frame, into which the positioning pins 14 and 15 are fittedone for one.

Placing the positioning pins 14 and 15 on the rear member 3 side is notdiscordant with the gist of the present invention.

Embodiment 6

FIG. 10 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 5 are given the same referential codes as thosegiven in FIG. 5 to avoid the repetition of the same descriptions.

In this embodiment, the distance L between the front and rear members 2and 3 of the main frame is determined by the stays 4 and 7 of the mainframe; the distance L becomes fixed as the lengthwise ends of stays 4and 7 are placed in contact with the inward surface 2 c of the frontmember 2 and the inward surface 3 c of the rear member 3.

This embodiment is an example of a recycling method characterized inthat in order to recycle the main frame of a recovered apparatus, theflat plate 2 a constituting the front plate of the main frame isreplaced with a flat plate which is partly different in configurationfrom the flat plate 2 a, and further, the replacement plate is attachedto the front member 2 from the inward surface 2 c side of the frontmember 2, that is, the surface which contributes to the fixing of thedistance L between the front and rear members 2 and 3.

With the provision of this structural arrangement, it is possible toimprove the level of the accuracy with which the components attached tothe front surface of the flat plate are positioned relative to the rearmember of the main frame.

The flat plate 2 a constituting the front plate of the front member ofthe main frame may be processed before, or after, its attachment to thefront member 2 of the main frame, or it may be replaced with a componentvirtually identical in configuration to the processed flat plate 2 a.

Although this embodiment is described with reference to the flat plateof the front member of the main frame, it is not intended to limit thescope of the present invention to the flat plate of the front member ofthe main frame. In other words, modifying the components of the mainframe other than the flat plate of the front member of the main frame,instead of, or as well as, the flat plate of the front member of themain frame, and attaching them to the main frame from the side otherthan the side from which the original components were attached to themain frame, is not discordant with the gist of the present invention.

Embodiment 7

FIG. 11 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 9 are given the same referential codes as thosegiven in FIG. 9 to avoid the repetition of the same descriptions.

Designated by a referential code 2 a is a flat plate constituting thefront plate of the main frame, and designated by referential codes 2 dand 2 e are supporting members which support the flat plate 2 a, or thefront plate, of the main frame.

This embodiment is an example of a recycling method characterized inthat in order to recycle the main frame, the flat plate 2 a constitutingthe front plate of the main frame is replaced with a flat plate which ispartially different in configuration from the flat plate 2 a, and alsothat the supporting members 2 d and 2 e which constitute the frontmembers, and to which the flat plate 2 a is attached, are made roughlyL-shaped in cross section.

Giving the front plate supporting members a roughly L-shaped crosssection improves the strength of the supporting members, making itpossible to reduce the amount of the material for the supporting memberswhile relying more on the supporting members, for the main framestrength.

Although this embodiment is described with reference to the front memberof the main frame, it is not intended to limit the scope of the presentinvention to the front member of the main frame. In other words,replacing the original components of the main frame other than the frontmember of the main frame, instead of, or as well as, the front member ofthe main frame, with components, which are partially different inconfiguration from the originals, is not discordant with the gist of thepresent invention.

Embodiment 8

FIG. 12 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 11 are given the same referential codes asthose given in FIG. 11 to avoid the repetition of the same descriptions.

This embodiment is an example of a recycling method characterized inthat in order to recycle the main frame, the flat plate 2 a constitutingthe front plate of the main frame is replaced with a flat plate which ispartially different in configuration from the flat plate 2 a, and alsothat the supporting member 2 d and 2 e which constitute the frontmembers, and to which the flat plate 2 a is attached, are made roughlyU-shaped in cross section.

Giving the front plate supporting members a roughly U-shaped crosssection improves the strength of the supporting members, making itpossible to reduce the amount of the material for the supporting memberswhile relying more on the supporting members, for the strength of themain frame.

Although this embodiment is described with reference to the front memberof the main frame, it is not intended to limit the scope of the presentinvention to the front member of the main frame. In other words,replacing the original components of the main frame other than theoriginal front member of the main frame, instead of, or as well as, theoriginal front member of the main frame with components which arepartially different in configuration from the originals, is notdiscordant with the gist of the present invention.

Embodiment 9

FIG. 13 is a drawing which best shows the characteristics of thisembodiment. In the drawing, the structural components of the main framesimilar to those in FIG. 11 are given the same referential codes asthose given in FIG. 11 to avoid the repetition of the same descriptions.

This embodiment is an example of a recycling method characterized inthat in order to recycle the main frame, the flat plate 2 a constitutingthe front plate of the main frame is replaced with a flat plate which ispartially different in configuration from the flat plate 2 a, and alsothat the supporting members 2 d and 2 e which constitute the frontmembers, and to which the flat plate 2 a is attached, are made hollow,and roughly square in cross section.

Making the front plate supporting members hollow, and roughly square incross section, improves the strength of the supporting members, makingit possible to reduce the amount of the material for the supportingmembers while relying more on the supporting members, for the main framestrength.

As is evident from the above descriptions of the seventh-ninthembodiments, bending the front plate supporting members of the mainframe at a single or plurality of lines parallel to the lengthwisedirection of the supporting members, so that the cross sections of thesupporting members have at least one corner, increases the strength ofthe supporting members. For example, in the case of the L-shaped crosssection, the cross sections of the supporting members have one corner,and in the case of the U-shaped cross section, they have two corners. Inthe case of the supporting members which are hollow and have the squarecross section, they have four corners.

Although this embodiment is described with reference to the front memberof the main frame, it is not intended to limit the scope of the presentinvention to the front member of the main frame. In other words, thecomponents of the main frame, which are bent as described above, may bethose other than the front member of the main frame, instead of, or aswell as, the front member of the main frame, and this is not discordantwith the gist of the present invention.

As for one of the configurations for the hollow supporting members 2 dand 2 e in this embodiment, it may be the configuration shown in FIG.14, which is disclosed in Japanese Laid-open Patent Application7-271131, or the like configurations.

FIG. 22 shows an example of an image forming apparatus compatible withthe above described recycling methods. The image from an originaldelivered to the reading portion from the original feeding apparatus 51is read by the reading/exposing apparatus 42, and is projected onto theperipheral surface of the photoconductive drum 40 having been charged bythe charging means 41, forming an electrostatic latent image. The latentimage is developed into a toner image, by the developing means 43. Thetoner image is transferred by the transferring means 44 onto thetransfer medium delivered from one of cassettes 47, 48, 49, and 50. Thetransferred toner image is fixed to the transfer medium by the fixingmeans 46. The transfer residual toner particles, that is, the tonerparticles remaining on the peripheral surface of the photoconductivedrum 40 after the toner image transfer, are recovered by the cleaningmeans 45. The recovered transfer residual toner particles are conveyedto the waste toner container 2 by the unshown waste toner conveyingmeans, and collected therein. The above described various means of thisimage forming apparatus are supported by the main frame 1 of the imageforming apparatus.

Embodiment 10

FIG. 15 is a vertical sectional view of an image forming apparatus, at aplane parallel to the front surface thereof, manufactured in accordancewith the present invention. This image forming apparatus is anelectrophotographic laser beam printer.

(1) General Structure of Image Forming Apparatus

In FIG. 15, a referential code 40 stands for the main assembly of theelectrophotographic image forming apparatus for forming an image on animage recording medium in the form of a sheet. The main assemblycontains the following functional devices and units; some of them may beexternally held by the main assembly.

-   -   1) Power source unit 10 for supplying the various portions of        the apparatus with electricity;    -   2) Control unit 20 for electrically controlling the various        portions of the apparatus, for storing image formation data, and        for processing image formation data;    -   3) Photoconductive drum holding toner cartridge unit 410 which        contains a cylindrical photoconductive drum, the peripheral        surface of which changes in potential level as it is exposed to        light, and a transfer roller for transferring a toner image onto        the recording medium, in addition to the toner which visualizes        picture elements by adhering to the exposed portions of the        peripheral surface of the photoconductive member;    -   4) Laser beam scanner unit 420 for scanning the peripheral        surface of the photoconductive drum with a beam of laser light        modulated with the image formation data;    -   5) Paper cassette 460, in the form of a box, for holding in        layers a plurality of recording papers P as recording mediums;    -   6) Sheet feeding unit 440 for conveying the recording papers P        from the paper cassette 460 while separating them one by one;    -   7) Registration roller unit 400 for positioning the leading edge        of each recording paper P with reference to the toner image        before transferring the toner image onto the recording paper P;    -   8) Fixing unit 430 for fixing the toner image having been        transferred onto the recording paper P, to the recording paper P        with the application of heat and pressure;    -   9) Sheet discharging unit 450 for discharging the recording        paper P with the fixed toner image, out of the apparatus main        assembly; and        -   the like devices and/or units.

The image forming apparatus may be connected to a means which enablesthe image forming apparatus to receive image formation data fromexternal apparatuses, a means which generates image formation data byreading an original, or the like means, so that the image formingapparatus is enabled to obtain image formation data and process them.These means may be integral parts of the image forming apparatus.

The paper cassette 460 comprises: a paper box 460; a holding plate 462for holding the recording papers P in layers; a spring 463 for keepingthe holding plate 462 pressed upward in order to keep the recordingpapers P on the holding plate 462 pressed upward; a trailing edgeregulating plate 464 for regulating the position of the trailing edge,in terms of the recording paper conveyance direction, of the recordingpaper P; an unshown lateral edge regulating plate for regulating theposition of the recording paper P in terms of the directionperpendicular to the recording paper conveyance direction; and the like.Further, the paper cassette 460 is structured so that it can be pulledout of the apparatus main assembly when replenishing the image formingapparatus with recording papers P, or in the like situations, and sothat the lateral edge regulating plate (unshown) and the trailing edgeregulating plate 464 can be moved according to the recording paper size.

The sheet feeding unit 440 of the paper cassette 460 is provided with aseparating pad 465, a sheet feeding roller 441, and a conveying rollerpair 442. The separating pad 465 has a high coefficient of friction. Thesheet feeding roller 441 separates the topmost recording paper P in thepaper box 460 from the rest of the recording papers in the paper box460, in coordination with the separating pad 465, and feeds therecording paper P into the apparatus main assembly. The conveying rollerpair 442 conveys the recording paper P toward the image forming portionof the apparatus main assembly, as the recording paper P is delivered tothe conveying roller pair 442. The sheet feeding unit 440 is alsoprovided with a recording paper detecting means for detecting whether ornot a recording paper P is present on the recording paper holding plate462, a recording paper size detecting means for detecting the size ofthe recording papers P in the paper box 460 and providing the apparatusmain assembly with the detected recording paper size, and the likemeans.

The registration roller unit 400 is provided with a recording paperleading edge detection sensor 401 and a registration roller pair 402.The recording paper leading edge detection sensor 401 detects theleading and trailing edges of the recording paper P as the recordingpaper P is passed by the sensor 401 one by one from the sheet feedingunit 440 of the paper cassette after being separated from the rest ofthe recording papers P in the paper box 460. The registration rollerpair 401 positions the recording paper P so that the leading edge of therecording paper P becomes perpendicular to the recording paperconveyance direction, and then, conveys the recording paper P to theimage forming portion, in coordination with the timing with which thetrailing end of the preceding recording paper P was detected by therecording paper leading edge detection sensor 401.

In an image forming operation, the following processes occur in thetoner cartridge unit 410 integrally comprising the photoconductive drum411. First the peripheral surface of the photoconductive drum 411, as anelectrostatic latent image bearing member, is uniformly charged by thecharging member 412. Then, the charged peripheral surface of thephotoconductive drum 411 is exposed to a scanning beam of laser lightemitted from the laser beam scanner unit 420 while being modulated withthe image formation data. As a result, an electrostatic latent image isformed on the photoconductive drum 411. Next, the toner as developer isadhered to the electrostatic latent image on the photoconductive drum411 by the development sleeve 113 as a developer bearing member. As aresult, a toner image is formed on the photoconductive drum 411. As thetoner image is formed, a recording paper P is passed through the contactarea between the peripheral surfaces of the photoconductive drum 411 anda transfer roller 414 while being pinched by the photoconductive drum411 and transfer roller 414. While the recording paper P is passedthrough the contact area, the toner image is transferred onto thesurface of the recording paper P in contact with the photoconductivedrum 411. Thereafter, the recording paper P is conveyed toward thefixing unit 430.

In the fixing unit 430, heat and pressure is applied to the toner on therecording paper P by the pressure roller 432 and fixing roller 431containing a heater, as the recording paper P is passed between the tworollers. As a result, the toner image is fixed to the recording paper P.

The sheet discharging unit 450 is provided with a discharge roller 451for discharging the recording paper P with the fixed image, out of theapparatus main assembly, and a sheet discharge roller 452 which isrotated by the rotation of the discharge roller 451. Thus, the recordingpaper P, to which the toner image was fixed in the fixing unit 430, isdischarged into the recording paper accumulating tray 47 (delivery tray)by the discharge rollers 451 and 452.

The delivery tray 471 is located on top of the image forming apparatusmain assembly 40. Therefore, a recording paper P begins to be conveyedupward from the sheet feeding portion of the paper cassette 460 locatedin the bottom portion of the apparatus main assembly. Then, after animage is formed thereon, the recording paper P is discharged upward. Thedirection indicated in FIG. 15 by an arrow mark W is the direction inwhich a recording paper P is discharged into the delivery tray 471.

Although not shown, the fixing unit 430, and the sheet discharging unit450 on the downstream side of the fixing unit 430, are each providedwith a detecting means for detecting whether or not the leading andtrailing ends of a recording paper P will have passed within apredetermined length of time.

(2) Unit Supporting Structure

FIG. 16 is a perspective view of an image forming apparatus in FIG. 15,from which exterior panels have been removed. FIG. 17 is a perspectiveview of the image forming apparatus in FIG. 16, the front plate of whichis outlined in the double-dot chain line, giving the impression that thefront plate was made transparent to show the components behind the frontplate. FIG. 18 is a perspective view of only the main frame of the imageforming apparatus in FIGS. 15 and 16.

A referential code 500 stands for the main frame of the image formingapparatus, and a referential code 501 stands for the bottom plate of themain frame 500. A referential code 502 stands for the rear plateperpendicular to the bottom plate 501, and a referential code 503 standsfor the front plate which is parallel to the rear plate 502 and isperpendicular to the bottom plate 501. There is a predetermined distancebetween the rear and front plates 502 and 503, A referential code 504stands for the horizontal stay which is located at the top of the mainframe and connects the front and rear plates 503 and 502.

The main frame 500 is a skeletal frame comprising at least the abovedescribed plates 501-503 and stay 504, which are formed as integralparts of the main frame, or discrete parts assembled to form the mainframe. This skeletal frame is referred to as the main frame. Variousunits which constitute the internal organs of an image formingapparatus, and the exterior panels, are attached to this main frame torealize an image forming apparatus as a merchandise.

The rear and front plates 502 and 503 of the main frame 500 are eachprovided with a plurality of holes. The holes of the former correspondin position to those of the latter, one for one. The shafts extendedfrom, or put through, the above described units are put through theseholes to support the units by the rear and front plates 502 and 503, inthe predetermined positions between the rear and front plates 502 and503.

For example, referring to FIG. 17, the laser beam scanner unit 420 isprovided with shafts J1 and J2 as mounting/supporting members whichperpendicularly extend from the lengthwise end surface of the unit 420on the front side (perpendicular to the front plate 503); although notshown, a plurality of shafts similar to the shafts J1 and J2perpendicularly extend from the lengthwise end surface of the unit 420on the rear side (perpendicular to the rear plate 502). These shafts areput through the holes h1 and h2 of the front plate 503, and the holes h3and h4 of the rear plate 502. As a result, the laser beam scanner unit420 is supported in the predetermined position in the main frame 500.

With the provision of the structural arrangements similar to that forthe laser beam scanner unit 420, the control unit 20, registrationroller unit 400, photoconductive drum holding toner cartridge unit 410,fixing unit 430, paper feeding unit 440, paper discharging unit 450, andthe like are supported in the predetermined positions in the main frame500.

(3) Reuse of Apparatus Main Frame

Recovered used image forming apparatuses are disassembled into theindividual components, units, and the like, to be reused to manufacturenew image forming apparatuses. In the case of this embodiment of thepresent invention, the apparatus frames 500 are reused to manufacture“new” image forming apparatuses. Referring to FIG. 18, the main frame500 is one of the main frames obtained by disassembling the recoveredused image forming apparatuses. In this main frame 500, a plurality ofthe aforementioned functional units capable of performing, one for one,various functions necessary to form an image on a recording medium, aresupported in the predetermined positions in the main frame 500, alongwith the device other than the aforementioned units. Then, these unitsand devices are wired, and the exterior panels are attached to the mainframe 500, completing an image forming apparatus as “new” merchandise.

When originally manufacturing the main frame 500, the pair of opposinglateral plates 502 and 503 of the main frame 500 are provided with agreater number of unit supporting holes than the minimum number of unitsupporting holes necessary for supporting the plurality of functionalunits of an image forming apparatus in accordance with an originalspecification (first specification), to make it easier to replace atleast one of the plurality of units attached to the recycled main frame500, with a unit different from the original unit, to place at least oneof the plurality of units in the position different from the originalone, to add a single or plurality of units different from the originalones, to add components to the original units, or to perform the likemodification, when reusing the main frame 500 to manufacture an imageforming in accordance with a specification (second specification)different from the first specification.

FIG. 19 shows an example of the reuse of the main frame 500. In thiscase, an image forming apparatus in accordance with the secondspecification is realized by placing a plurality of functional units,some of which are different from the counterparts in a recovered usedimage forming apparatus, that is, an image forming apparatus inaccordance with the first specification, in the original positions, orthe positions different from the original positions. In FIG. 19, thefront panel 503 is outlined with double-dot chain lines, as shown inFIG. 17, giving the impression that the front panel 503 is madetransparent to show the units behind the front panel 503.

In FIG. 19, a referential code 1020 stands for a control unit Bdifferent from the control unit 20, and a referential code 1400 standsfor a registration roller unit B different from the registration rollerunit 400. A referential code 1410 stands for a photoconductive drumholding toner cartridge unit B different from the photoconductive drumholding toner cartridge unit 410, and referential code 1420 stands for alaser beam scanner unit B different from the laser beam scanner unit420. A referential code 1430 stands for a fixing unit B different fromthe fixing unit 430, and a referential code 1440 stands for a sheetfeeding unit B different from the sheet feeding unit 440. A referentialcode 1450 stands for a sheet discharging unit B different from the sheetdischarging unit 450.

Further, the laser beam scanner unit B1420 is placed in a positiondifferent from that of the laser beam scanner unit 420, in the mainframe 500, being supported by the holes of the rear plate 502, differentfrom the holes h1 and h2 of the rear plate 502, and the holes of thefront plate 503, different from the holes h3 and h4 of the front plate503.

It should be noted here that all the new units attached to the mainframe recycled from the recovered image forming apparatus in accordancewith the first specification to manufacture an image forming apparatusin accordance with the second specification, do not need to be differentin specification and/or positioning from the original units which wereattached to the main frame when the main frame belonged to an imageforming apparatus in accordance with the first specification, and thatthe new units different in specification and/or positioning from theoriginal units and the new units identical in specification and/orpositioning to the original units may be attached in an appropriatecombination to the main frame recycled from the recovered image formingapparatus.

FIG. 20 shows another example of the reuse of the main frame 500. Inthis case, in order to manufacture an image forming apparatus inaccordance with the second specification using the main frame recycledfrom a recovered used image forming apparatus in accordance with thefirst specification, a minimum of one of the new units attached to themain frame 500 recycled from the recovered used image forming apparatusis made different in specification and/or positioning from thecorresponding unit among the original units which were attached to therecycled main frame 500, or a single or plurality of new units and/orcomponents different from any of the original units and/or componentsare added to the list of the new units and/or components attached to therecycled main frame 500 to manufacture an image forming apparatus inaccordance with the second specification.

In FIG. 20, a referential code 2020 stands for a control unit Cdifferent from the control units 20 and B1020, and a referential code2400 stands for a registration roller unit C different from theregistration roller units 400 and B1400. A referential code 2410 standsfor a photoconductive drum holding toner cartridge unit C different fromthe photoconductive drum holding toner cartridges 410 and B1410, andreferential code 2420 stands for a laser beam scanner unit C differentfrom the laser beam scanner units 420 and B1420. A referential code 2430stands for a fixing unit C different from the fixing units 430 andB1430, and a referential code 2440 stands for a sheet feeding unit Cdifferent from the sheet feeding units 440 and B1440. A referential code2450 stands for a sheet discharging unit C different from the sheetdischarging units 450 and B1450.

For example, the laser beam scanner unit 2420 is placed in the positiondifferent from those of the laser beam scanner units 420 and B1420, inthe main frame 500.

It should be noted here that all the new units attached to the mainframe recycled from the recovered image forming apparatus in accordancewith the first specification to manufacture an image forming apparatusin accordance with the second specification, do not need to be differentin specification and/or positioning from the original units which wereattached to the main frame when the main frame belonged to an imageforming apparatus in accordance with the first specification, and thatthe new units different in specification and/or positioning from theoriginal units and the new units identical in specification and/orpositioning to the original units may be attached in an appropriatecombination to the main frame recycled from the recovered image formingapparatus.

FIG. 21 shows an image forming apparatus realized by attaching new unitsdifferent in specification and/or positioning from those in the imageforming apparatuses in FIGS. 15, 19, and 20 to the main frame recycledfrom the recovered used image forming apparatus. This image formingapparatus is substantially different in the paper conveyance path fromthe image forming apparatus in FIG. 15. In order to clarify thedifference, FIG. 21, a vertical sectional view of the image formingapparatus, shows the positional relationship among the functional units,in terms of the vertical direction of the image forming apparatus. Inthe drawing, the main frame is not shown.

In FIG. 21, a referential code 3400 stands for a registration rollerunit D different from the registration roller units 400, B1400, andC2400. A referential code 3410 stands for a photoconductive drum holdingtoner cartridge unit D different from the photoconductive drum holdingtoner cartridge units 410, B1410, and C2410, and referential code 3420stands for a laser beam scanner unit D different from the laser beamscanner units 420, B1420, and C2420. A referential code 3430 stands fora fixing unit D different from the fixing units 430, B1430, and C2430,and a referential code 3440 stands for a sheet feeding unit D differentfrom the sheet feeding units 440, B1440, and C2440. A referential code3450 stands for a sheet discharging unit D different from the sheetdischarging units 450, B1450, and C2450, and a referential code 3460stands for an intermediary conveyer unit connecting the photoconductivedrum holding toner cartridge D3410 and fixing unit 3430. A referentialcode 3471 stands for a delivery tray in which discharged recordingpapers are accumulated.

In the image forming apparatus in which functional units are disposed asshown in FIG. 21, an image is formed on the recording paper while therecording paper is virtually horizontally conveyed after it begins to beconveyed from the sheet feeding portion. After the image formation, therecording medium is further conveyed in the same direction, that is,horizontally, and is horizontally discharged from the apparatus mainassembly. With the provision of this structural arrangement, therecording medium can be discharged into a lower position, with referenceto the floor surface, than the position into which the recording mediumis discharged from the image forming apparatus in which the functionalunits are disposed as shown in FIG. 15. In other words, an image formingapparatus in which the units are disposed as shown in FIG. 21 isadvantageous in that it is easier for a shorter person to use.

It should be also noted here that all the new units attached to the mainframe recycled from the recovered image forming apparatus in accordancewith the first specification to manufacture an image forming apparatusin accordance with the second specification, do not need to be differentin specification and/or positioning from the original units which wereattached to the main frame when the main frame belonged to an imageforming apparatus in accordance with the first specification, and thatthe new units different in specification and/or positioning from theoriginal units and the new units identical in specification and/orpositioning to the original units may be attached in an appropriatecombination to the main frame recycled from the recovered image formingapparatus.

As is evident from the above descriptions of the embodiments of thepresent invention, the provision of the above described structuralarrangements makes it easier to replace a single or plurality of theoriginal units with a single or plurality of units different from theoriginal unit to modify the image forming apparatus. For example, theoriginal control unit can be easily replaced to increase processingspeed; the original laser beam scanner unit can be easily replaced toincrease resolution; the original sheet feeding unit can be easilyreplaced to improve paper separation performance; and/or the originalfixing unit can be easily replaced to reduce power consumption.

Further, the provision of the above described structural arrangementsmakes it possible not only to replace a single or plurality of currentunits with a single or plurality of units different in function,performance, and/or positioning from the current units, or to rearrangethe current units, but also to add a single or plurality of units new infunction, to manufacture an image forming apparatus different inspecification from the recovered used image forming apparatus from whichthe main frame was recycled. For example, although the precedingembodiments of the present invention were described with reference to animage forming apparatus comprising a single photoconductive drum holdingmonochromatic toner cartridge unit, this monochromatic image formingapparatus can be remanufactured into a color image forming apparatus, bythe addition of a plurality of photoconductive drum holding tonercartridge units different in toner color.

In order to realize the above described objects, the rear and frontplates 502 and 503 of the apparatus main frame 500 are provided inadvance with an excessive number of holes, that is, a greater number ofholes than the minimum number of holes necessary for the manufacture ofthe image forming apparatus in FIG. 15, so that the rear and front plate502 and 503 are made compatible even with units different inspecification and/or positioning from those in the image formingapparatus in FIG. 15.

While the invention has been described with reference to the structuresdisclosed herein, it is not confined to the details set forth, and thisapplication is intended to cover such modifications or changes as maycome within the purposes of the improvements or the scope of thefollowing claims.

1. A recycling method in an apparatus having a part, comprising: a partremoval step of removing a part from said apparatus; a mounting step ofmounting to said apparatus a part having a specification different fromthat of the removed part.
 2. A method according to claim 1, wherein thepart having the different specification is mounted to a position atwhich the removed part has been mounted.
 3. A method according to claim1, wherein the part having the different specification is mounted to aposition different from a position at which the removed part is mounted.4. A method according to claim 1, wherein the part has an engagingportion for engagement with said apparatus, and said apparatus has ahole portion for engagement with the engaging portion.
 5. A methodaccording to claim 4, wherein said apparatus has a number of holeportions which is larger than a number which is necessary to mount thepart.
 6. A method according to claim 5, wherein the part having thedifferent specification is mounted to a position different from aposition at which the removed part is mounted.
 7. A method according toclaim 1, wherein said apparatus after the part having the differentspecification has a specification which is different from aspecification of said apparatus before the part having the differentspecification is mounted.
 8. A method according to claim 4, wherein theengaging portion is provided at opposite ends of the part.
 9. A methodaccording to claim 8, wherein the engaging portions are opposite endportions of a shaft member penetrating the part.
 10. A method accordingto claim 1, wherein said apparatus is an image forming apparatus, andthe part is a unit of a plurality of units having different functionsfor image formation.
 11. A method according to claim 1, wherein saidapparatus is an image forming apparatus, and the part is a plate-likemember constituting a part of a frame of said image forming apparatus.12. A method according to claim 11, wherein the specification of thepart of which is the plate-like is a shape thereof.
 13. A methodaccording to claim 11, wherein the frame has a side plate member onwhich the plate-like member is fixed, and a cross-sectionalconfiguration of the side plate member has at least one bent portion.14. An image forming apparatus recycled by a method comprising: a partremoving step of removing a part from said image forming apparatus; amounting step of mounting to said apparatus a part having aspecification different from that of the removed part.
 15. A methodaccording to claim 14, wherein the part having the differentspecification is mounted to a position at which the removed part hasbeen mounted.
 16. A method according to claim 14, wherein the parthaving the different specification is mounted to a position differentfrom a position at which the removed part is mounted.
 17. A methodaccording to claim 14, wherein the part has an engaging portion forengagement with said apparatus, and said apparatus has a hole portionfor engagement with the engaging portion.
 18. A method according toclaim 17, wherein said apparatus has a number of hole portions which islarger than a number which is necessary to mount the part.
 19. A methodaccording to claim 18, wherein the part having the differentspecification is mounted to a position different from a position atwhich the removed part is mounted.
 20. A method according to claim 14,wherein said apparatus after the part having the different specificationhas a specification which is different from a specification of saidapparatus before the part having the different specification is mounted.21. A method according to claim 17, wherein the engaging portion isprovided at opposite ends of the part.
 22. A method according to claim21, wherein the engaging portions are opposite end portions of a shaftmember penetrating the part.
 23. A method according to claim 14, whereinsaid apparatus is an image forming apparatus, and the part is a unit ofa plurality of units having different functions for image information.24. A method according to claim 14, wherein said apparatus is an imageforming apparatus, and the part is a plate-like member constituting apart of a frame of said image forming apparatus.
 25. A method accordingto claim 24, wherein the specification of the part of which is theplate-like is a shape thereof.
 26. A method according to claim 24,wherein the frame has a side plate member on which the plate-like memberis fixed, and a cross-sectional configuration of the side plate memberhas at least one bent portion.
 27. An apparatus of a first type which isrecyclable into an apparatus of a second type, said apparatus of thefirst type comprising: an image forming unit having a function of imageformation; and a supporting member for supporting said image formingunit, said supporting member including a plurality of supportingportions for supporting said image forming unit and a supportingportion, different from said plurality of supporting portions, forsupporting an image forming unit of the apparatus of the second type.